Pre-Engineered/Prefabricated Wall Assembly

ABSTRACT

A pre-engineered/prefabricated wall assembly that has inner and outer sidewall panels of rigid insulation material that acts as both thermal insulation and concrete forms. The inner and outer sidewall panels are connected by connecting rods that secures a metal stud wall frame to the interior of the wall assembly, and a metal stud wall frame to the exterior of the wall assembly. The connecting rods serve to align the inner and outer sidewall panels separate from, and parallel to, each other, thereby providing a space for rebar and concrete to form a reinforced concrete wall. The mortar-less brick/stone veneer is attached to the wall assembly by inserting an attaching rod through the outer and inner sidewall panels, and is secured with a mechanical fastener, thereby securing the mortar-less brick/stone veneer in place until the poured concrete permanently secures the mortar-less brick/stone veneer to the exterior of the wall assembly.

REFERENCE TO RELATED APPLICATIONS

This patent application claims the benefit of U.S. Provisional Application No. 61/340,456 filed on Mar. 18, 2010, and U.S. Provisional Application No. 61/284,169 filed on Dec. 14, 2009, the disclosures of which are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to building materials, and particularly to a pre-engineered/prefabricated wall assembly complete with inner and outer sidewall panels that serve as both thermal insulation and forms for the pouring of concrete, with wall studs attached to the inner sidewall panel to form wall framing to which wallboards such as gypsum board and other wall coverings may be attached; and similar wall studs attached to the outer sidewall panel to form wall framing to which exterior sheathing, vinyl siding, wood siding, composite siding, and other exterior sidings may be attached, and to which wall ties may be attached for securing brick, stone, architectural concrete, and other exterior veneers. The present invention also includes a pre-engineered/prefabricated wall assembly whereby the outer sidewall panel and the metal studs attached to the outer sidewall panel are omitted and exterior wall sheathing such as plywood, OSB board, or other exterior wall sheathing are attached to the exterior of the inner sidewall panel, thus forming a wall assembly complete with wall studs attached to the interior of the sidewall panel, and exterior sheathing attached to the exterior of the inner sidewall panel. The present invention also includes a mortar-less brick/stone veneer that may be attached to the outer sidewall panel of the wall assembly.

2. Description of the Related Art

Homes, schools, hospitals and other residential and commercial buildings are sometimes constructed using the “Poured Cinder Block” building method where hollow cored cinder blocks (a.k.a. cement masonry units “CMU's”) are used. The cinder blocks are typically sealed in place with mortar so that the hollow cores of the cinder blocks face upwards. In poured cinder block wall construction, the cinder blocks serve as concrete forms into which concrete is poured to form a concrete wall. However, workers set the concrete forms (cinder blocks) only eight inches high and sixteen inches wide (approx. one square foot) at a time. The workers repeat this process over, and over, and then; using this extremely expensive and time consuming method of setting concrete forms, after enough blocks are laid, the cinder block forms are finally ready for the pouring of concrete. However, once the cinder blocks are laid and the cores filled with concrete, there is still no wall framing in place for the attachment of wall board or other wall coverings and to accommodate the placement of electrical wiring and other utilities; nor is there any thermal insulation in place. There is also no exterior furring strips or wall framing on the exterior side of the cinder block wall to accommodate the attachment of exterior sheathing, vinyl siding, wood siding, composite siding, or the attachment of wall ties for laying brick and other exterior veneers. In poured cinder block wall construction, the laying of cinder blocks, the erection of wall framing, and the placement of thermal insulation are operations separate and apart. These separate operations are very time consuming and greatly increases construction costs.

In poured cinder block wall construction, a concrete foundation is normally laid and then a row known as a “course” of cinder blocks are set in mortar on the foundation. Another layer of mortar is placed on top of the first course and a second course is then laid. In this manner a cinder block wall is constructed; but to achieve a cinder block wall that is both level and plumb, a great deal of skill and time is required. The time and skill required to construct a cinder block wall raises construction costs. Another problem with cinder block walls is that in their unfinished state they do not present a very pleasant appearance and therefore require finishing. Finishing a cinder block wall usually involves attaching a veneer such as brick or stone, painting, applying stucco, vinyl siding, or attaching some other type of exterior siding or veneer. The finishing of a cinder block wall requires considerable time and skill and adds substantial costs to wall construction. Another problem associated with applying exterior finishes to cinder block walls is that it is extremely difficult to attach siding materials such as wood siding, vinyl siding, metal siding, and other sidings to the hard surface of cinder blocks. To attach these siding materials, it is generally necessary to drill holes into the cinder blocks for the placement of metal or plastic anchors. Furring strips are then attached to these anchors, and in turn, the siding is attached to the furring strips. The attachment of these siding materials is both time consuming and adds considerable costs to wall construction. In most cases, it is also necessary to frame the interior of cinder block walls with wooden studs, metal studs, or furring strips to accommodate the placement of thermal insulation, the placement of electrical wiring, and for the attachment of gypsum board or other wall covering. This installation of wall framing is time consuming and also adds to the cost of wall construction. In an attempt to strengthen cinder block walls to withstand high velocity winds from hurricanes and tornados, sometimes steel reinforcement bar (“rebar”) is placed into the cinder block cores and then concrete is poured into the cores of the cinder blocks. The placement of rebar and the pouring of concrete into the cores of cinder blocks adds considerable costs to wall construction and in many cases does not accomplish the desired structural effect due to the fact that the concrete often “honey cones” when poured into the cores of the cinder blocks. Another problem with poured cinder block wall construction is the fact that a wall is as strong as its weakest point and the weakest point of poured cinder block walls are the mortar joints and the webs and end walls of the cinder blocks themselves. The honey coning and weak mortar joints and webs of poured cinder block wall construction are inherent weaknesses that renders poured cinder block wall construction structurally inferior to traditionally “formed” reinforced concrete wall construction. Structurally inferior poured cinder block walls are especially susceptible to wind loads from hurricane and tornado force winds when compared to traditionally formed reinforced concrete wall construction.

Various methods of solving the problems of poured cinder block walls have been put forward. A concrete “grout” has been developed that flows more evenly into the cinder block cores than does regular concrete. While this grout may help prevent honey coning and voids in the cinder block cores, it does not solve the problem of the structural weakness of the cinder block mortar joints, webs, and end walls, and does little to improve structural load factors involving hurricane and tornado force winds. Some have omitted erecting interior framing and elected to “glue” the wall board directly to the interior of the cinder block wall, however, when wall board is glued directly to the cinder blocks there is no space provided between the wall board and cinder blocks for the placement of thermal insulation or the placement of electrical wiring and other utilities. Therefore, for the construction of reinforced concrete homes and other residential and commercial buildings a pre-engineered/prefabricated wall assembly for the erection of reinforced concrete walls that solves the aforementioned problems is desired.

SUMMERY OF THE INVENTION

The subject pre-engineered/prefabricated wall assembly (“wall assembly”) incorporates numerous features into its wall system that reduces the time and cost of constructing a reinforced concrete wall. The wall assembly has the following components: The first components are the inner and outer sidewall panels that serve as forms to provide a space for the placement of rebar and the pouring of concrete. Since these inner and outer sidewall panels are constructed of polystyrene, polyurethane, or other rigid insulation materials, these sidewall panels also serve as thermal insulation that has a far greater “R-Value” than standard wall insulation, greatly conserving energy and reducing heating and cooling costs.

The second component is the wall framing attached to the inner sidewall panel consisting of a lower metal track and an upper metal track into which metal studs are placed to form metal stud wall framing. The metal stud framing provides a surface for the attachment of gypsum board or other wall covering and provides a space between the inner sidewall panel and the wall covering to run electrical wiring and other utilities. The metal stud framing is attached to the wall assembly by metal connecting rods and/or threaded bolts inserted through the inner and outer sidewall panels and secured with threaded nuts, speed washers, or other mechanical fasteners.

The third component is the metal stud framing attached to the exterior side of the wall assembly by means of connecting rods and/or threaded bolts inserted through the inner and outer sidewall panels and then secured with threaded nuts, speed washers, or other mechanical fasteners. The exterior wall framing may be used to attach wall ties for the laying of mortared brick, mortared stone, architectural concrete, and other exterior veneers; and for securing wood siding, composite siding, vinyl siding or other exterior sidings.

The fourth component is a mortar-less brick/stone veneer that also includes architectural concrete, and other exterior veneers used in wall construction. An attaching rod is attached to the back of the brick, stone, rock, architectural concrete and other exterior veneers by gluing, welding, screwing, or other means of attachment. Once the attaching rod is secured to the mortar-less brick/stone veneer, it is inserted through the exterior side of wall sheathing, the exterior side of insulated concrete forms (ICF's), the exterior side of cinder blocks, and through other wall materials, and is then secured on the interior side of said wall sheathing, wall forms, cinder blocks, insulated concrete forms (ICF's), and through other wall materials, with a mechanical fastener such as a speed clip (washer), threaded nut, or other mechanical fastener.

The wall assembly is pre-engineered in accordance with project drawings and are then prefabricated in various assembly sizes, complete with window and door openings, and window and door headers and footers. The prefabricated wall assembly is prefabricated with inner and outer sidewall panels that serve as both concrete forms and thermal insulation, with metal stud framing attached to the interior side of the wall assembly, with metal stud framing attached to the exterior side of the wall assembly, and is then shipped to the construction site ready to install. Since the wall assembly is both pre-engineered and prefabricated for an exact fit, the wall assembly is very easy to erect by only two workers, greatly reducing the cost of wall construction.

The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

The foregoing has outlined, rather broadly, the preferred feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention and that such other structures do not depart from the spirit and scope of the invention in its broadest form.

BRIEF DESCRIPTION OF THE DRAWINGS

Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claim, and the accompanying drawings in which similar elements are given similar reference numerals.

FIG. 1 is a perspective view of the pre-engineered/prefabricated wall assembly in accordance with the principles of the present invention;

FIG. 2A is a front view of the wall assembly showing the metal stud wall framing attached to the interior side of the wall assembly;

FIG. 2B is a view along the line 2B-2B of FIG. 2A of the wall assembly showing the inner sidewall panel and the interior wall framing attached to the interior side of the wall assembly, and the outer sidewall panel and the exterior wall framing attached to the exterior side of the wall assembly;

FIG. 2C is a view along the line 2C-2C of FIG. 2A of the wall assembly showing the inner sidewall panel and the interior wall framing attached to the interior side of the wall assembly, and the outer sidewall panel and the exterior wall framing attached to the exterior side of the wall assembly;

FIG. 2D is an enlarged view showing a connecting rod connecting the inner and outer sidewall panels to the interior and exterior metal stud wall framing;

FIG. 2E is view of the wall assembly showing the exterior wall framing attached to the exterior of the wall assembly;

FIG. 3A is a view of the wall assembly showing the mortar-less brick/stone veneer attached to the exterior side of the wall assembly with the exterior wall framing omitted;

FIG. 3B is a view along the line 3B-3B of FIG. 3A of the wall assembly showing the mortar-less brick/stone veneer secured to the exterior side of the wall assembly with an attaching rod and with the exterior wall framing omitted;

FIG. 3C is an enlarged view showing the mortar-less brick/stone veneer attaching rod penetrating through the sidewall panels of the wall assembly. The mortar-less brick/stone veneer attaching rod is then secured on the interior side of the wall assembly with a mechanical fastener securing the mortar-less brick/stone veneer in place prior to pouring concrete at the construction site;

FIGS. 4A, 4B, and 4C show the mortar-less brick/stone exterior veneer and the attaching rod with mechanical fastener.

FIG. 5A is a front view of a wall assembly secured to a floor slab or footing and attached to an adjacent wall assembly;

FIG. 5B is a view along the line 5B-5B of FIG. 5A of the wall assembly showing the attachment to an adjacent wall assembly;

FIG. 5C is a view along the line 5C-5C of FIG. 5A showing the wall assembly secured to floor slab or footing and attached of an upper wall assembly;

FIG. 5D is a horizontal section showing the construction of a typical corner; and

FIG. 6 is a typical installation drawing showing the exact location for installing the pre-engineered wall assemblies, along with pre-engineered headers and footers for doors and windows, where P-1, P-2 and P-3 represents pre-engineered wall assemblies, H-1 represents a door header, H-2 represents a pre-engineered window header, and F-1 represents a pre-engineered window footer.

FIG. 7A is a front view of the wall assembly showing the metal stud wall framing attached to the interior side of the wall assembly;

FIG. 7B is a view along the line 7B-7B of FIG. 7A of the wall assembly showing the inner sidewall panel and the interior wall framing attached to the interior side of the wall assembly, and the exterior wall sheathing attached to the exterior side of the wall assembly;

FIG. 7C is a view along the line 7C-7C of FIG. 7A of the wall assembly showing the inner sidewall panel and the interior wall framing attached to the interior side of the wall assembly, and the exterior wall sheathing attached to the exterior side of the wall assembly;

FIG. 7D is an enlarged view showing a connecting rod connecting the interior wall framing and the exterior wall sheathing to the inner sidewall panel;

FIG. 7E is view of the wall assembly showing the exterior wall sheathing attached to the exterior of the wall assembly;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is a pre-engineered/prefabricated wall assembly (“wall assembly”) designated as 100 in the drawings. FIG. 1 shows a perspective view of pre-engineered/prefabricated wall assembly 100. The wall assembly 100 is made up of several components making up a single unit as shown in FIG. 1.

The first of the components is the outer sidewall panel designated as 110 and the inner sidewall panel designated as 120 shown in FIG. 1 and in FIGS. 2A, 2B, 2C, 2D, 3A, 3C, 5A, 5B and 5C. Outer sidewall panel 110 and inner sidewall panel 120 serve to form a wall cavity for the placement of rebar and the pouring of concrete. Inner sidewall panel 120 and outer sidewall panel 110 are constructed of polystyrene, polyurethane, or other insulation materials to also serve as wall insulation that has a far greater R-value than the fiberglass insulation used in traditional building methods and therefore provide far greater savings on heating and cooling costs.

The second component to the wall assembly 100 is the interior wall framing fabricated with a lower metal track 200 and an upper metal track 210 into which metal wall studs 220 are attached as shown in detail in FIG. 1A, 2A, 2B, 2C, 2D, 2E, 3B,3C, 5A, 5B, and 5C. The metal wall studs 220 provides a surface for the attachment of gypsum board or other wall covering and also provides a space between the inner sidewall panel 120 and the wall covering to run electrical wiring and other utilities.

The third component to the wall assembly 100 is the exterior wall framing fabricated with a lower metal track 200 and an upper metal track 210 into which metal wall studs 220 are attached as shown in detail in FIG. 1A, 2A, 2B, 2C, 2D, 3B, 3C, 5A, 5B, and 5C. The metal wall studs 220 provide a surface for the attachment of wall ties for the laying of mortared brick, mortared stone, architectural concrete, and other exterior veneers; and for securing exterior wall sheathing, wood siding, composite siding, vinyl siding, and other exterior sidings.

The fourth component is connecting rod 230 and mechanical fastener 240 shown in FIG. 2B, 2C, and more fully defined in FIG. 2D. Connecting rod 230 is first attached to the interior wall framing and then inserted through inner sidewall panel 120, outer sidewall panel 110, and the outer wall framing and then secured on the exterior of wall stud 220 with mechanical fasteners 240. Connecting rod 230 is provided in various lengths to facilitate various spacing widths between inner sidewall panel 120 and outer sidewall panel 110 for the pouring of concrete in various wall thicknesses.

Wall assembly 100 is secured to the floor, the footing, or to the foundation of homes or other residential or commercial buildings using fasteners 510 as shown in FIGS. 5A and 5C. Wall assembly 100 is then secured to the adjacent and adjoining wall assemblies 100. In this manner a wall is thus formed and is ready for the placement of rebar and the pouring of concrete to form a wall with a solid reinforced concrete center.

The fifth component to wall assembly 100 is a mortar-less brick/stone veneer 310 as detailed in FIG. 3A, 3B, and 3C, and more fully defined in FIGS. 4A, 4B and 4C. A hole is first placed into the back side of the mortar-less brick/stone veneer 310. Attaching rod 410 is then inserted into said hole and secured by gluing, or other means of attachment.

Mortar-less brick/stone veneer 310 is attached to wall assembly 100 by first inserting attaching rod 410 through outer sidewall panel 110 and then through inner sidewall panel 120 and then securing attaching rod 410 with mechanical fastener 420 as detailed in FIG. 3A and 3B, and as is more fully detailed in FIG. 3C. Attaching rod 410 and mechanical fastener 420 secure brick/stone veneer 310 in place until concrete, grout, or other filler is poured into the space provided between inner sidewall panel 120 and outer sidewall panel 110. Once concrete or other filler is poured into the space provided between sidewall panel 120 and sidewall panel 110, brick/stone veneer 510 is permanently secured in place as shown in FIG. 3C.

The sixth component to wall assembly 100 is exterior wall sheathing 710 as shown in FIGS. 7A, 7B, 7C, 7D and 7E whereby the outer sidewall panel 110, along with lower metal track 200, upper metal track 210, and metal studs 220 are omitted to form a separate wall assembly constructed of metal track 200, upper metal track 210, and metal studs 220, along with inner sidewall panel 120 and exterior wall sheathing 710 attached to wall assembly 100 with connecting rod 230 and secured with mechanical fastener 240 as more clearly detailed in enlarged FIG. 7D.

By constructing the body of the different embodiments of the pre-engineered/prefabricated wall assembly described above, the inner and outer sidewall panels acts as concrete forms as well as thermal insulation, the metal tracks and studs located on the interior of the wall assembly forms interior wall framing for the attachment of gypsum board and other wall coverings, while the metal tracks and studs located on the exterior of the wall assembly forms exterior wall framing for the attachment of exterior veneers and sidings.

While there have been shown and described and pointed out the fundamental novel features of the invention as applied to the preferred embodiments, it will be understood that the foregoing is considered as illustrative only of the principles of the invention and not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are entitled. 

1. A pre-engineered/prefabricated wall assembly comprising: a first inner sidewall panel running the length and width of the wall assembly; and a second outer sidewall panel spaced from the first sidewall panel running the length and width of the wall assembly.
 2. The pre-engineered/prefabricated wall assembly according to claim 1, wherein the inner sidewall panel runs parallel to and equidistance from the outer sidewall panel; and wherein a space is provide between the inner sidewall panel and the outer sidewall panel for the placing of rebar and the pouring of concrete.
 3. The pre-engineered/prefabricated wall assembly according to claim 1, wherein the inner and outer sidewall panels are constructed of polystyrene, polyurethane, or other rigid insulation material.
 4. The pre-engineered/prefabricated wall assembly according to claim 1, further comprising: a lower horizontal metal track and an upper horizontal metal track coupled to and running the length of the inner sidewall panel; and a plurality of vertical metal wall studs located in the lower horizontal metal track and the upper horizontal metal track and secured thereto with metal framing screws; wherein a rectangular wall frame is formed consisting of upper and lower horizontal metal tracks and vertical metal wall studs that form interior wall framing for the attachment of gypsum board or other wall covering, and provides a space for the placement of electrical wiring or other utilities.
 5. The pre-engineered/prefabricated wall assembly according to claim 1, further comprising: a lower horizontal metal track and an upper horizontal metal track coupled to and running the length of the outer sidewall panel; and a plurality of vertical metal wall studs located in the lower horizontal metal track and the upper horizontal metal track and secured therein with metal framing screws; wherein a rectangular wall frame is formed consisting of upper and lower horizontal metal tracks and vertical metal wall studs that provide exterior wall framing for the attachment of wall ties to secure brick, stone, architectural concrete, or other exterior veneers, or for the attachment of exterior wall sheathing, vinyl siding, wood siding, composite siding, or other sidings.
 6. The pre-engineered/prefabricated wall assembly according to claim 2, further comprising: at least one connecting rod for securing a metal stud wall frame to the wall assembly; wherein the at least one connecting rod is inserted through both the inner and outer wall panels, and wherein the at least one connecting rod is secured in place on the exterior side of the wall assembly by at least one threaded nut, speed washer, or other mechanical fastener.
 7. The pre-engineered/prefabricated wall assembly according to claim 6 wherein the at least one connecting rod comes with different lengths which allow for a spacing of different widths between the inner sidewall panel and outer sidewall panel for attachment of rebar and pouring of concrete in various wall thicknesses.
 8. The pre-engineered/prefabricated wall assembly according to claim 7 wherein an attaching rod located in a preformed hole in a mortar-less veneer is adapted to secured the mortar-less veneer to the wall.
 9. A mortar-less brick, mortar-less stone, mortar-less rock, mortar-less architectural concrete, or other mortar-less veneer wherein a hole is placed into the back of said mortar-less veneer during the manufacturing process.
 10. A pre-engineered/prefabricated wall assembly comprising: an inner sidewall panel constructed of polystyrene, polyurethane, or other rigid insulation;
 11. The pre-engineered/prefabricated wall assembly according to claim 10, further comprising: a lower horizontal metal track and an upper horizontal metal track coupled to and running the length of the inner sidewall panel; and a plurality of vertical metal wall studs located in the lower horizontal metal track and the upper horizontal metal track and secured thereto with metal framing screws; wherein a rectangular wall frame is formed consisting of upper and lower horizontal metal tracks and vertical metal wall studs that form interior wall framing for the attachment of gypsum board or other wall covering, and provides a space for the placement of electrical wiring or other utilities.
 12. The pre-engineered/prefabricated wall assembly according to claim 10, further comprising: exterior wall sheathing material running the length and width of the wall assembly for the attachment of wall ties to secure brick, stone, architectural concrete, or other exterior veneers, and for the attachment of vinyl siding, wood siding, composite siding, or other sidings.
 13. The pre-engineered/prefabricated wall assembly according to claim 10, further comprising: at least one connecting rod, threaded rod, threaded bolt, screw, or other connecting devise for securing the exterior wall sheathing to the wall assembly; wherein the at least one connecting rod is inserted through the interior metal stud wall framing, the inner sidewall panel, and the exterior wall sheathing; wherein at least one connecting rod, threaded rod, threaded bolt, screw, or other connecting devise is secured in place on the exterior side of the wall assembly by at least one threaded nut, speed washer, or other mechanical fastener. 